2. List of related manuals
DRIVE MANUALS Code (EN)
ACS310 Short User’s Manual 3AUA0000044200 2)
ACS310 User’s Manual 3AUA0000044201
OPTION MANUALS Code (EN)
MFDT-01 FlashDrop User’s Manual 3AFE68591074 2)
MREL-01 Relay Output Extension Module User's Manual for ACS310/
ACS350
3AUA0000035974 2)
MUL1-R1 Installation Instructions for ACS150, ACS310 and ACS350 3AFE68642868 1, 2)
MUL1-R3 Installation Instructions for ACS150, ACS310 and ACS350 3AFE68643147 1, 2)
MUL1-R4 Installation Instructions for ACS310 and ACS350 3AUA0000025916 1, 2)
SREA-01 Ethernet Adapter Module Quick Start-up Guide 3AUA0000042902 2)
SREA-01 Ethernet Adapter Module User’s Manual 3AUA0000042896 3)
MAINTENANCE MANUALS Code (EN)
Guide for Capacitor Reforming in ACS50, ACS55, ACS150, ACS310,
ACS350 and ACS/ACH550
3AFE68735190
1) Multilingual
2)
Delivered as a printed copy with the drive / optional equipment
3)
Delivered in PDF format with the drive / optional equipment
All manuals are available in PDF format on the Internet. See section Document library on the
Internet on page 333.
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15. Safety 15
1
Safety
What this chapter contains
The chapter contains safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, motor or driven equipment. Read the safety
instructions before you work on the drive.
Use of warnings
Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment, and advise on how to avoid the danger. The
following warning symbols are used in this manual:
Electricity warning warns of hazards from electricity which can cause physical
injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the equipment.
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16. 16 Safety
Safety in installation and maintenance
These warnings are intended for all who work on the drive, motor cable or motor.
Electrical safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
Only qualified electricians are allowed to install and maintain the drive!
• Never work on the drive, motor cable or motor when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that
there is no voltage between the drive input phases U1, V1 and W1 and the
ground.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may carry dangerous
voltage even when the input power of the drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive.
• If a drive whose EMC filter is not disconnected is installed on an IT system (an
ungrounded power system or a high resistance-grounded [over 30 ohms] power
system), the system will be connected to ground potential through the EMC filter
capacitors of the drive. This may cause danger or damage the drive.
• If a drive whose EMC filter is not disconnected is installed on a corner grounded
TN system, the drive will be damaged.
• All ELV (extra low voltage) circuits connected to the drive must be used within a
zone of equipotential bonding, ie within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. This is accomplished by a proper factory
grounding.
Note:
• Even when the motor is stopped, dangerous voltage is present at the power
circuit terminals U1, V1, W1 and U2, V2, W2.
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17. Safety 17
General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
• The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for
replacement.
• Make sure that dust from drilling does not enter the drive during the installation.
Electrically conductive dust inside the drive may cause damage or lead to
malfunction.
• Ensure sufficient cooling.
Safe start-up and operation
These warnings are intended for all who plan the operation, start up or operate the
drive.
General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
• Before adjusting the drive and putting it into service, make sure that the motor and
all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at speeds
above and below the speed provided by connecting the motor directly to the
power line.
• Do not activate automatic fault reset functions if dangerous situations can occur.
When activated, these functions will reset the drive and resume operation after a
fault.
• Do not control the motor with an AC contactor or disconnecting device
(disconnecting means); use instead the control panel start and stop keys and
or external commands (I/O or fieldbus). The maximum allowed number of
charging cycles of the DC capacitors (ie power-ups by applying power) is two per
minute and the maximum total number of chargings is 15 000.
Note:
• If an external source for start command is selected and it is ON, the drive will start
immediately after an input voltage break or fault reset unless the drive is
configured for 3-wire (a pulse) start/stop.
• When the control location is not set to local (LOC not shown on the display), the
stop key on the control panel will not stop the drive. To stop the drive using the
control panel, first press the LOC/REM key and then the stop key .LOC
REM
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19. Introduction to the manual 19
2
Introduction to the manual
What this chapter contains
The chapter describes applicability, target audience and purpose of this manual. It
describes the contents of this manual and refers to a list of related manuals for more
information. The chapter also contains a flowchart of steps for checking the delivery,
installing and commissioning the drive. The flowchart refers to chapters/sections in
this manual.
Applicability
The manual is applicable to the ACS310 drive firmware version 4.00E or later. See
parameter 3301 FIRMWARE on page 202.
Target audience
The reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations in the United States are given.
Purpose of the manual
This manual provides information needed for planning the installation, installing,
commissioning, using and servicing the drive.
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20. 20 Introduction to the manual
Contents of this manual
The manual consists of the following chapters:
• Safety (page 15) gives safety instructions you must follow when installing,
commissioning, operating and servicing the drive.
• Introduction to the manual (this chapter, page 19) describes applicability, target
audience, purpose and contents of this manual. It also contains a quick
installation and commissioning flowchart.
• Operation principle and hardware description (page 23) describes the operation
principle, layout, power connections and control interfaces, type designation label
and type designation information in short.
• Mechanical installation (page 29) tells how to check the installation site, unpack,
check the delivery and install the drive mechanically.
• Planning the electrical installation (page 35) tells how to check the compatibility of
the motor and the drive and select cables, protections and cable routing.
• Electrical installation (page 45) tells how to check the insulation of the assembly
and the compatibility with IT (ungrounded) and corner grounded TN systems as
well as connect power cables, control cables and embedded fieldbus.
• Installation checklist (page 45) contains a checklist for checking the mechanical
and electrical installation of the drive.
• Start-up and control with I/O (page 57) tells how to start up the drive as well as
how to start, stop, change the direction of the motor rotation and adjust the motor
speed through the I/O interface.
• Application macros (page 99) gives a brief description of each application macro
together with a wiring diagram showing the default control connections. It also
explains how to save a user macro and how to recall it.
• Program features (page 111) describes program features with lists of related user
settings, actual signals, and fault and alarm messages.
• Actual signals and parameters (page 149) describes actual signals and
parameters. It also lists the default values for the different macros.
• Fieldbus control with embedded fieldbus (page 265) tells how the drive can be
controlled by external devices over a communication network using embedded
fieldbus.
• Fault tracing (page 287) tells how to reset faults and view fault history. It lists all
alarm and fault messages including the possible cause and corrective actions.
• Maintenance and hardware diagnostics (page 303) contains preventive
maintenance instructions and LED indicator descriptions.
• Technical data (page 307) contains technical specifications of the drive, eg
ratings, sizes and technical requirements as well as provisions for fulfilling the
requirements for CE and other marks.
• Dimensions (page 323) shows dimension drawings of the drive.
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21. Introduction to the manual 21
• Further information (inside of the back cover, page 333) tells how to make product
and service inquiries, get information on product training, provide feedback on
ABB Drives manuals and find documents on the Internet.
Related documents
See List of related manuals on page 2.
Categorization by frame size
The ACS310 is manufactured in frame sizes R0…R4. Some instructions and other
information which only concern certain frame sizes are marked with the symbol of the
frame size (R0…R4). To identify the frame size of your drive, see the table in section
Ratings on page 308.
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22. 22 Introduction to the manual
Quick installation and commissioning flowchart
Task See
Identify the frame size of your drive: R0…R4. Operation principle and hardware description:
Type designation key on page 27
Technical data: Ratings on page 308
Plan the installation: select the cables, etc.
Check the ambient conditions, ratings and
required cooling air flow.
Planning the electrical installation on page 35
Technical data on page 307
Unpack and check the drive. Mechanical installation: Unpacking on page
31
If the drive will be connected to an IT
(ungrounded) or corner grounded system,
check that the internal EMC filter is not
connected.
Operation principle and hardware description:
Type designation key on page 27
Electrical installation: Checking the
compatibility with IT (ungrounded) and corner
grounded TN systems on page 46
Install the drive on a wall or in a cabinet. Mechanical installation on page 29
Route the cables. Planning the electrical installation: Routing the
cables on page 39
Check the insulation of the input cable and the
motor and the motor cable.
Electrical installation: Checking the insulation
of the assembly on page 45
Connect the power cables. Electrical installation: Connecting the power
cables on page 47
Connect the control cables. Electrical installation: Connecting the control
cables on page 49
Check the installation. Installation checklist on page 55
Commission the drive. Start-up and control with I/O on page 57
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23. Operation principle and hardware description 23
3
Operation principle and
hardware description
What this chapter contains
The chapter briefly describes the operation principle, layout, type designation label
and type designation information. It also shows a general diagram of power
connections and control interfaces.
Operation principle
The ACS310 is a wall or cabinet mountable drive for controlling AC motors.
The figure below shows the simplified main circuit diagram of the drive. The rectifier
converts three-phase AC voltage to DC voltage. The capacitor bank of the
intermediate circuit stabilizes the DC voltage. The inverter converts the DC voltage
back to AC voltage for the AC motor.
AC motor
M
3~
Rectifier Intermediate
circuit
AC supply
Inverter
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24. 24 Operation principle and hardware description
Product overview
Layout
The layout of the drive is presented below. The figure shows a frame size R2 drive.
The construction of the different frame sizes R0…R4 varies to some extent.
1 Cooling outlet through top cover
2 Mounting holes
3 Panel cover (a) / Basic Control Panel (b) /
Assistant Control Panel (c)
4 Terminal cover
5 Panel connection
6 Option connection
7 FlashDrop connection
8 Power OK and Fault LEDs. See section
LEDs on page 306.
9 EMC filter grounding screw (EMC).
Note: The screw is on the front in frame
size R4.
10 Varistor grounding screw (VAR)
11 RS-485 connection
12 Jumper J701 for connecting RS-485
termination resistor
13 I/O connections
14 Switch S1 for selecting voltage or current
for analog inputs
15 Input power connection (U1, V1, W1) and
motor connection (U2, V2, W2). (Braking
chopper connection is disabled.)
16 I/O clamping plate
17 Clamping plate
18 Clamps
2
4
3b
3a
3c
5
6
7
8
13
2
1110
9
8
15
18
18
16
17
1
12
14
Covers on (R2) Covers off (R2)
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25. Operation principle and hardware description 25
Power connections and control interfaces
The diagram gives an overview of connections. I/O connections are parameterable.
See chapter Application macros on page 99 for I/O connections for the different
macros and chapter Electrical installation on page 45 for installation in general.
RONO
RONC
3
9
DI1
DI2
DI3
DI4
DI5
+24 VAux. voltage output
+24 V DC, max. 200 mA
DOSRC
GND
DCOM
DOOUT
DOGND
Digital/frequency output,
PNP transistor type
30 V DC, max. 100 mA
Relay output
250 V AC / 30 V DC / 6 A
V
mAGND
+10V
Reference voltage
+10 V DC, max. 10 mA
AI2Analog input 2
GND
AI1Analog input 1
0…10 V
SCRScreen
Analog output
0…20 mAAI1
AI2
L1
3-phase power
supply,
200…480 V AC
U2
V2
W2
AC motor
M
3 ~
EMC
VAR
EMC filter grounding screw
Varistor grounding screw
ROCOM
PROGRAMMABLE RELAY
AND DIGITAL OUTPUTS
Control panel
(RJ-45)
Modbus RTU
(RS-232)
Output relay
module MREL-01
11 17
18
19
20
21
22
AO 7
GND 8
12
13
14
15
16
10
L2
L3
PE
6
5
1
2
SHIELD
B
A
GND_A
23
24
25
26
Modbus RTU
(RS-485)
PROGRAMMABLE
DIGITAL INPUTS
4
FlashDrop
U1
V1
W1
S1
J701
8
6
6
DI5 can also be used
as a frequency input
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26. 26 Operation principle and hardware description
Type designation label
The type designation label is attached to the left side of the drive. An example label
and explanation of the label contents are shown below.
ACS310-03E-09A7-4
IP20 / UL Open type lllllllllllllllllllllllllllllllllllllll
S/N MYYWWRXXXX
4 kW (5 HP) llllllllllllllllllllllllllllllllllllllll
U1 3~380…480 V 3AUA0000039632
I1 15.0 A
f1 48…63 Hz
U2 3~0…U1 V
I2 9.7 A RoHS
f2 0…500 Hz
1 Type designation, see section Type designation key on page 27
2 Degree of protection by enclosure (IP and UL/NEMA)
3 Nominal ratings, see section Ratings on page 308.
4 Serial number of format MYYWWRXXXX, where
M: Manufacturer
YY: 08, 09, 10, …, for 2008, 2009, 2010, …
WW: 01, 02, 03, … for week 1, week 2, week 3, …
R: A, B, C, … for product revision number
XXXX: Integer starting every week from 0001
5 ABB MRP code of the drive
6 CE marking and C-Tick, C-UL US and RoHS marks (the label of your drive shows the valid
markings)
5
6
4
3
2
1
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27. Operation principle and hardware description 27
Type designation key
The type designation contains information on the specifications and configuration of
the drive. You find the type designation on the type designation label attached to the
drive. The first digits from the left express the basic configuration, for example
ACS310-03E-09A7-4. The optional selections are given after that, separated by +
signs, for example +J404. The explanations of the type designation selections are
described below.
ACS310 product series
03 = 3-phase input
3-phase
In format xxAy, where xx indicates the integer part and y the fractional part,
eg 09A7 means 9.7 A.
For more information, see section Ratings on page 308.
2 = 200…240 V AC
4 = 380…480 V AC
Input voltage range
E = EMC filter connected, 50 Hz frequency
U = EMC filter disconnected, 60 Hz frequency
Configuration
J404 = ACS-CP-C Basic Control Panel 1)
J400 = ACS-CP-A Assistant Control Panel 2)
R700 = ACS310 User’s Manual in English (3AUA0000044201 [EN])
R701 = ACS310 User’s Manual in German (3AUA0000048396 [DE])
R702 = ACS310 User’s Manual in Italian (3AUA0000048398 [IT])
R707 = ACS310 User’s Manual in French (3AUA0000048400 [FR])
R708 = ACS310 User’s Manual in Spanish (3AUA0000048401 [ES])
1) The ACS310 is compatible with ACS-CP-C Basic Control Panel Rev M or later.
2) The ACS310 is compatible with ACS-CP-A Assistant Control Panel Rev E or later (new
panel series manufactured since 2007 with serial number XYYWWRXXXX, where year
YY = 07 or greater and revision R = E, F, G, …)
(The ACS310 is compatible with ACS-CP-D Assistant Control Panel Rev P or later. Unlike
the other panels, the ACS-CP-D is ordered with a separate material code.)
Options
ACS310-03E-09A7-4+J404+...
Output current rating
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29. Mechanical installation 29
4
Mechanical installation
What this chapter contains
The chapter tells how to check the installation site, unpack, check the delivery and
install the drive mechanically.
Checking the installation site
The drive may be installed on the wall or in a cabinet. Check the enclosure
requirements for the need to use the NEMA 1 option in wall installations (see chapter
Technical data on page 307.
The drive can be installed in three different ways, depending on the frame size:
a) back mounting (all frame sizes)
b) side mounting (frame sizes R0…R2)
c) DIN rail mounting (all frame sizes).
The drive must be installed in an upright position.
Check the installation site according to the requirements below. Refer to chapter
Dimensions on page 323 for frame details.
Requirements for the installation site
Operation conditions
See chapter Technical data on page 307 for the allowed operation conditions of the
drive.
Wall
The wall should be as close to vertical and even as possible, of non-flammable
material and strong enough to carry the weight of the drive.
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30. 30 Mechanical installation
Floor
The floor/material below the installation should be non-flammable.
Free space around the drive
The required free space for cooling above and below the drive is 75 mm (3 in). No
free space is required on the sides of the drive, so drives can be installed side by
side.
Required tools
To install the drive, you need the following tools:
• screwdrivers (as appropriate for the mounting hardware used)
• wire stripper
• tape measure
• drill (if the drive will be installed with screws/bolts)
• mounting hardware: screws or bolts (if the drive will be installed with screws/
bolts). For the number of screws/bolts, see With screws on page 32.
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31. Mechanical installation 31
Unpacking
The drive (1) is delivered in a package that also contains the following items (frame
size R2 shown in the figure):
• plastic bag (2) including clamping plate (also used for I/O cables in frame sizes
R3 and R4), I/O clamping plate (for frame sizes R0…R2), clamps and screws
• panel cover (3)
• mounting template, integrated into the package (4)
• short user’s manual (5)
• possible options (Basic Control Panel, Assistant Control Panel or complete User’s
Manual).
Checking the delivery
Check that there are no signs of damage. Notify the shipper immediately if damaged
components are found.
Before attempting installation and operation, check the information on the type
designation label of the drive to verify that the drive is of the correct type. See section
Type designation label on page 26.
2
1
3
5
4
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32. 32 Mechanical installation
Installing
The instructions in this manual cover drives with the IP20 degree of protection. To
comply with NEMA 1, use the MUL-R1, MUL-R3 or MUL-R4 option kit, which is
delivered with multilingual installation instructions (3AFE68642868, 3AFE68643147
or 3AUA0000025916, respectively).
Install the drive
Install the drive with screws or on a DIN rail as appropriate.
Note: Make sure that dust from drilling does not enter the drive during the installation.
With screws
1. Mark the hole locations using for example the mounting template cut out from the
package. The locations of the holes are also shown in the drawings in chapter
Dimensions on page 323. The number and location of the holes used depend on
how the drive is installed:
a) back mounting (frame sizes R0…R4): four holes
b) side mounting (frame sizes R0…R2): three holes; one of the bottom holes is
located in the clamping plate.
2. Fix the screws or bolts to the marked locations.
1 22
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33. Mechanical installation 33
3. Position the drive onto the screws on the wall.
4. Tighten the screws in the wall securely.
On DIN rail
1. Click the drive to the rail.
To detach the drive, press the release lever on top of the drive (1b).
3 4
1 1b
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34. 34 Mechanical installation
Fasten clamping plates
1. Fasten the clamping plate to the plate at the bottom of the drive with the provided
screws.
2. For frame sizes R0…R2, fasten the I/O clamping plate to the clamping plate with
the provided screws.
1
2
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35. Planning the electrical installation 35
5
Planning the electrical
installation
What this chapter contains
The chapter contains the instructions that you must follow when checking the
compatibility of the motor and drive, and selecting cables, protections, cable routing
and way of operation for the drive.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if the
recommendations given by ABB are not followed, the drive may experience problems
that the warranty does not cover.
Implementing the AC power line connection
See the requirements in section Electric power network specification on page 314.
Use a fixed connection to the AC power line.
WARNING! As the leakage current of the device typically exceeds 3.5 mA, a
fixed installation is required according to IEC 61800-5-1.
Selecting the supply disconnecting device (disconnecting
means)
Install a hand-operated supply disconnecting device (disconnecting means) between
the AC power source and the drive. The disconnecting device must be of a type that
can be locked to the open position for installation and maintenance work.
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36. 36 Planning the electrical installation
European union
To meet the European Union Directives, according to standard EN 60204-1, Safety of
Machinery, the disconnecting device must be one of the following types:
• a switch-disconnector of utilization category AC-23B (EN 60947-3)
• a disconnector having an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
• a circuit breaker suitable for isolation in accordance with EN 60947-2.
Other regions
The disconnecting device must conform to the applicable safety regulations.
Checking the compatibility of the motor and drive
Check that the 3-phase AC induction motor and the drive are compatible according to
the rating table in section Ratings on page 308. The table lists the typical motor power
for each drive type.
Selecting the power cables
General rules
Dimension the input power and motor cables according to local regulations.
• The input power and the motor cables must be able to carry the corresponding
load currents. See section Ratings on page 308 for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
the conductor in continuous use. For US, see section Additional US requirements
on page 38.
• The conductivity of the PE conductor must be equal to that of the phase
conductor (same cross-sectional area).
• 600 V AC cable is accepted for up to 500 V AC.
• Refer to chapter Technical data on page 307 for the EMC requirements.
A symmetrical shielded motor cable (see the figure below) must be used to meet the
EMC requirements of the CE and C-Tick marks.
A four-conductor system is allowed for input cabling, but a shielded symmetrical
cable is recommended.
Compared to a four-conductor system, the use of a symmetrical shielded cable
reduces electromagnetic emission of the whole drive system as well as motor bearing
currents and wear.
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37. Planning the electrical installation 37
Alternative power cable types
Power cable types that can be used with the drive are presented below.
Motor cable shield
To function as a protective conductor, the shield must have the same cross-sectional
area as the phase conductors when they are made of the same metal.
To effectively suppress radiated and conducted radio-frequency emissions, the shield
conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires. The better and tighter the shield, the lower the
emission level and bearing currents.
Symmetrical shielded cable: three phase
conductors, a concentric or otherwise
symmetrically constructed PE conductor
and a shield
Motor cables
(recommended for input cables also)
PE
conductor
and shield
Shield Shield
PE
PE
Allowed as input cables
A four-conductor system: three phase
conductors and a protective conductor
Note: A separate PE conductor is required
if the conductivity of the cable shield is not
sufficient for the purpose.
Shield
PEPE
Insulation jacket Copper wire screen Cable core
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38. 38 Planning the electrical installation
Additional US requirements
Type MC continuous corrugated aluminium armor cable with symmetrical grounds or
shielded power cable is recommended for the motor cables if metallic conduit is not
used.
The power cables must be rated for 75 °C (167 °F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor and control wiring. Do not
run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
Six-conductor (three phases and three ground) type MC continuous corrugated
aluminium armor cable with symmetrical grounds is available from the following
suppliers (trade names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cable is available from the following suppliers:
• Belden
• LAPPKABEL (ÖLFLEX)
• Pirelli.
Selecting the control cables
General rules
All analog control cables and the cable used for the frequency input must be shielded.
Use a double-shielded twisted pair cable (Figure a, for example JAMAK by Draka NK
Cables) for analog signals. Employ one individually shielded pair for each signal. Do
not use common return for different analog signals.
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39. Planning the electrical installation 39
A double-shielded cable is the best alternative for low-voltage digital signals, but a
single-shielded or unshielded twisted multipair cable (Figure b) is also usable.
However, for frequency input, always use a shielded cable.
Run analog and digital signals in separate cables.
Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals are run as twisted pairs.
Never mix 24 V DC and 115/230 V AC signals in the same cable.
Relay cable
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL)
has been tested and approved by ABB.
Control panel cable
In remote use, the cable connecting the control panel to the drive must not exceed
3 m (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables are installed on separate trays. Avoid
long parallel runs of motor cables with other cables to decrease electromagnetic
interference caused by the rapid changes in the drive output voltage.
Where control cables must cross power cables make sure that they are arranged at
an angle as near to 90 degrees as possible.
The cable trays must have good electrical bonding to each other and to the grounding
electrodes. Aluminium tray systems can be used to improve local equalizing of
potential.
Double-shielded twisted
multipair cable
Single-shielded twisted
multipair cable
a b
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40. 40 Planning the electrical installation
A diagram of the cable routing is shown below.
Control cable ducts
Drive
Motor cable
Power cable
min. 300 mm (12 in)
Motor cable
min. 200 mm (8 in)
Input power cable
Control cables
90° min. 500 mm (20 in)
Lead 24 V and 230 V control cables in
separate ducts inside the cabinet.
Not allowed unless the 24 V cable is
insulated for 230 V or insulated with an
insulation sleeving for 230 V.
230 V24 V 230 V24 V
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41. Planning the electrical installation 41
Protecting the drive, input power cable, motor and motor
cable in short circuit situations and against thermal
overload
Protecting the drive and input power cable in short-circuit situations
Arrange the protection according to the following guidelines.
1)
Size the fuses according to instructions given in chapter Technical data on page 307. The
fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent
damage to adjoining equipment in case of a short-circuit inside the drive.
2)
Circuit breakers which have been tested by ABB with the ACS350 can be used. Fuses must
be used with other circuit breakers. Contact your local ABB representative for the approved
breaker types and supply network characteristics.
WARNING! Due to the inherent operating principle and construction of circuit
breakers, independent of the manufacturer, hot ionized gases may escape
from the breaker enclosure in case of a short-circuit. To ensure safe use, special
attention must be paid to the installation and placement of the breakers. Follow the
manufacturer’s instructions.
Protecting the motor and motor cable in short-circuit situations
The drive protects the motor and motor cable in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Circuit diagram Short-circuit protection
Protect the drive and input
cable with fuses or a
circuit breaker. See
footnotes 1) and 2).M
3~
Distribution
board
Input cable
M
3~
Drive
I>
1)
2)
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42. 42 Planning the electrical installation
Protecting the drive, motor cable and input power cable against
thermal overload
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal
overload switch or a circuit breaker must be used for protecting each cable and
motor. These devices may require a separate fuse to cut off the short-circuit current.
Protecting the motor against thermal overload
According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. It is also possible to connect a motor temperature measurement to
the drive. The user can tune both the thermal model and the temperature
measurement function further by parameters.
The most common temperature sensors are:
• motor sizes IEC180…225: thermal switch (for example Klixon)
• motor sizes IEC200…250 and larger: PTC or Pt100.
For more information on the thermal model, see section Motor Thermal Protection on
page 130. For more information on the temperature measurement function see
section Motor temperature measurement through the standard I/O on page 139.
Using residual current devices (RCD) with the drive
ACS310-03x drives are suitable to be used with residual current devices of Type B.
Other measures for protection in case of direct or indirect contact, such as separation
from the environment by double or reinforced insulation or isolation from the supply
system by a transformer, can also be applied.
Implementing a bypass connection
WARNING! Never connect the supply power to the drive output terminals U2,
V2 and W2. Power line voltage applied to the output can result in permanent
damage to the drive.
If frequent bypassing is required, employ mechanically connected switches or
contactors to ensure that the motor terminals are not connected to the AC power line
and drive output terminals simultaneously.
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43. Planning the electrical installation 43
Protecting the contacts of relay outputs
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
Equip inductive loads with noise attenuating circuits (varistors, RC filters [AC] or
diodes [DC]) in order to minimize the EMC emission at switch-off. If not suppressed,
the disturbances may connect capacitively or inductively to other conductors in the
control cable and form a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the I/O terminal block.
Drive
relay
output
Drive
relay
output
Drive
relay
output
Varistor
RC filter
Diode
230 V AC
24 V DC
230 V AC
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45. Electrical installation 45
6
Electrical installation
What this chapter contains
The chapter tells how to check the insulation of the assembly and the compatibility
with IT (ungrounded) and corner grounded TN systems as well as connect power
cables, control cables and embedded fieldbus.
WARNING! The work described in this chapter may only be carried out by a
qualified electrician. Follow the instructions in chapter Safety on page 15.
Ignoring the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests (for example hi-pot
or megger) on any part of the drive as testing can damage the drive. Every drive has
been tested for insulation between the main circuit and the chassis at the factory.
Also, there are voltage-limiting circuits inside the drive which cut down the testing
voltage automatically.
Input power cable
Check the insulation of the input power cable according to local regulations before
connecting to the drive.
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46. 46 Electrical installation
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is connected to the motor and disconnected from the
drive output terminals U2, V2 and W2.
2. Measure the insulation resistance between each phase
conductor and the Protective Earth conductor using a
measuring voltage of 500 V DC. The insulation resistance
of an ABB motor must exceed 10 Mohm (reference value
at 25 °C or 77 °F). For the insulation resistance of other
motors, please consult the manufacturer’s instructions.
Note: Moisture inside the motor casing will reduce the insulation resistance. If
moisture is suspected, dry the motor and repeat the measurement.
Checking the compatibility with IT (ungrounded) and
corner grounded TN systems
WARNING! If a drive whose EMC filter is not disconnected is installed on an IT
system (an ungrounded power system or a high resistance-grounded [over
30 ohms] power system), the system will be connected to ground potential through
the EMC filter capacitors of the drive. This may cause danger or damage the drive.
If a drive whose EMC filter is not disconnected is installed on a corner grounded TN
system, the drive will be damaged.
1. If you have an IT (ungrounded) or corner grounded TN system, disconnect the
internal EMC filter by removing the EMC screw. For 3-phase U-type drives (with
type designation ACS310-03U-), the EMC screw is already removed at the factory
and replaced by a plastic one.
ohm
U1
3~
MV1
W1
PE
Note: In frame size R4
the EMC screw is located
to the right of terminal W2.
1
EMC
VAR
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47. Electrical installation 47
Connecting the power cables
Connection diagram
U2 V2 W2
INPUT
1)
Drive
For alternatives, see section
Selecting the supply
disconnecting device
(disconnecting means) on
page 35.
OUTPUT
U1 V1 W1
Motor
3 ~
V1
U1 W1
PE
PE
L1 L2 L3
1)
Ground the other end of the PE conductor at the distribution board.
2)
Use a separate grounding cable if the conductivity of the cable shield is insufficient (smaller
than the conductivity of the phase conductor) and there is no symmetrically constructed
grounding conductor in the cable. See section Selecting the power cables on page 36.
Note:
Do not use an asymmetrically constructed motor cable.
If there is a symmetrically constructed grounding conductor in the motor cable in addition to
the conductive shield, connect the grounding conductor to the grounding terminal at the drive
and motor ends.
Route the motor cable, input power cable and control cables separately. For more
information, see section Routing the cables on page 39.
Grounding of the motor cable shield at the motor end
For minimum radio frequency interference:
• ground the cable by twisting the shield as follows:
flattened width > 1/5 · length
• or ground the cable shield 360 degrees at the lead-
through of the motor terminal box. a b
b > 1/5 · a
2)
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48. 48 Electrical installation
Connection procedure
1. Fasten the grounding conductor (PE) of the input power cable under the
grounding clamp. Connect the phase conductors to the U1, V1 and W1 terminals.
Use a tightening torque of 0.8 N·m (7 lbf·in) for frame sizes R0…R2, 1.7 N·m
(15 lbf·in) for R3, and 2.5 N·m (22 lbf·in) for R4.
2. Strip the motor cable and twist the shield to form as short a pigtail as possible.
Fasten the twisted shield under the grounding clamp. Connect the phase
conductors to the U2, V2 and W2 terminals. Use a tightening torque of 0.8 N·m
(7 lbf·in) for frame sizes R0…R2, 1.7 N·m (15 lbf·in) for R3, and 2.5 N·m (22 lbf·in)
for R4.
3. Secure the cables outside the drive mechanically.
1
1
2
2
2
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49. Electrical installation 49
Connecting the control cables
I/O terminals
The figure below shows the I/O terminals. Tightening torque is 0.4 N·m / 3.5 lbf·in.
Voltage and current selection for analog inputs
Switch S1 selects voltage (0 [2]…10 V / -10…10 V) or current (0 [4]…20 mA /
-20…20 mA) as the signal types for analog inputs AI1 and AI2. The factory settings
are unipolar voltage for AI1 (0 [2]…10 V) and unipolar current for AI2 (0 [4]…20 mA),
which correspond to the default usage in the application macros. The switch is
located to the left of I/O terminal 9 (see the I/O terminal figure above).
X1A:
1: SCR
2: AI1
3: GND
4: +10 V
5: AI2
6: GND
7: AO
8: GND
9: +24 V
10: GND
11: DCOM
12: DI1
13: DI2
14: DI3
15: DI4
16: DI5 digital or frequency input
X1B:
17: ROCOM
18: RONC
19: RONO
20: DOSRC
21: DOOUT
22: DOGND
X1C:
23: SCR
24: B
25: A
26: GND_A
mA
V
S1
X1A X1B
X1CJ701
AI1
AI2
J701: Connects 120 ohm termination resistor. See page
54.
S1: Selects voltage or current as the signal types for
analog inputs AI1 and AI2.
AI1
AI2
Top position: I (0 [4]…20 mA, default for AI2; or -20…20 mA)
Bottom position: U (0 [2]…10 V, default for AI1; or -10…10 V)
S1
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50. 50 Electrical installation
Voltage and current connection for analog inputs
Bipolar voltage (-10…10 V) and current (-20…20 mA) are also possible. If a bipolar
connection is used instead of a unipolar one, see section Programmable analog
inputs on page 120 for how to set parameters accordingly.
PNP and NPN configuration for digital inputs
You can wire the digital input terminals in either a PNP or NPN configuration.
External power supply for digital inputs
For using an external +24 V supply for the digital inputs, see the figure below.
Frequency input
If DI5 is used as a frequency input, see section Frequency input on page 123 for how
to set parameters accordingly.
SCR
AI
+10V
1…10 kohm
Unipolar voltage
+10 V GND -10 V
Bipolar voltage Unipolar/Bipolar current
Use external power supply.
GND
SCR
AI
GND
SCR
AI
GND
9 +24V
10 GND
11 DCOM
12 DI1
13 DI2
14 DI3
15 DI4
16 DI5
9 +24V
10 GND
11 DCOM
12 DI1
13 DI2
14 DI3
15 DI4
16 DI5
X1X1
NPN connection (sink)PNP connection (source)
NPN connection (sink)PNP connection (source)
9 +24V
10 GND
11 DCOM
12 DI1
13 DI2
14 DI3
15 DI4
16 DI5
9 +24V
10 GND
11 DCOM
12 DI1
13 DI2
14 DI3
15 DI4
16 DI5
X1X1
+24 V DC
0 V DC
0 V DC
+24 V DC
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51. Electrical installation 51
Connection example of a two-wire sensor
Hand/Auto, PID Control, PFC Control and SPFC Control macros (see section
Application macros on page 99) use analog input 2 (AI2). The macro wiring diagrams
for these macros show the connection when a separately powered sensor is used.
The figure below gives an example of a connection using a two-wire sensor.
Note: The sensor is supplied through its current output. Thus the output signal must
be 4…20 mA.
X1A
5 AI2 Process actual value measurement or reference,
4…20 mA, Rin = 100 ohm6 GND
…
9 +24V Auxiliary voltage output, non-isolated,
+24 V DC, max. 200 mA10 GND
P
I
4…20 mA
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52. 52 Electrical installation
Default I/O connection diagram
The default connection of the control signals depends on the application macro in
use, which is selected with parameter 9902 APPLIC MACRO.
The default macro is the ABB Standard macro. It provides a general purpose I/O
configuration with three constant speeds. Parameter values are the default values
given in section Default values with different macros on page 151. For information on
other macros, see chapter Application macros on page 99.
The default I/O connections for the ABB standard macro are given in the figure below.
X1A
1 SCR Signal cable shield (screen)
2 AI1 Output frequency reference: 0…10 V
3 GND Analog input circuit common
4 +10V Reference voltage: +10 V DC, max. 10 mA
5 AI2 Not in use by default. 0…10 V
6 GND Analog input circuit common
7 AO Output frequency value: 0…20 mA
8 GND Analog output circuit common
9 +24V Auxiliary voltage output: +24 V DC, max. 200 mA
10 GND Auxiliary voltage output common
11 DCOM Digital input common
12 DI1 Stop (0) / Start (1)
13 DI2 Forward (0) / Reverse (1)
14 DI3 Constant speed selection 1)
15 DI4 Constant speed selection 1)
16 DI5 Acceleration and deceleration selection 2)
X1B
17 ROCOM Relay output 1
No fault [Fault (-1)]18 RONC
19 RONO
20 DOSRC Digital output, max. 100 mA
No fault [Fault (-1)]21 DOOUT
22 DOGND
max. 500 ohm
1…10 kohm
3)
1)
See parameter group 12 CONSTANT
SPEEDS:
2)
0 = ramp times according to parameters
2202 and 2203.
1 = ramp times according to parameters
2205 and 2206.
3)
360 degree grounding under a clamp.
Tightening torque = 0.4 N·m / 3.5 lbf·in.
DI3 DI4 Operation (parameter)
0 0 Set speed through AI1
1 0 Speed 1 (1202)
0 1 Speed 2 (1203)
1 1 Speed 3 (1204)
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